Electrolytic solution for promoting electrolysis of water

ABSTRACT

An electrolytic solution that increases the efficiency of energy use and gas production of a wide range of electrolytic devices, that can be adapted to specific devices and to changes in the metal composition and configuration of conductive elements in electrolytic systems, and that reduces maintenance of the such systems. The electrolytic solution comprising a major solute and a minor solute combined proportionately and dissolved in a predetermined quantity of water; said major solute comprising dry pellets, flakes or combinations thereof comprising about 83% to 87% potassium hydroxide and about 0.4% to 0.7 of a carbonate, and minimal amounts of iron compounds and minimal amounts of calcium. The minor solute comprises about 4.0% to 6.0% of a bicarbonate and up to 3.0% sodium chloride, wherein said solutes are combined with said predetermined quantity of water to yield the electrolytic solution.

FIELD OF THE INVENTION

The present invention relates to the electrolysis of water to produce acombustible gas. More specifically, the present invention relates toelectrolytic solutions that promote the electrolysis of water, and evenmore specifically, the present invention relates to an electrolyticsolution that promotes the more efficient generation of hydrogen gas andoxygen through the electrolysis of water using well known devices andthat also specifically promotes the generation of a new, combustible gasproduced by a new electrolytic device.

BACKGROUND OF THE INVENTION

Hydrogen gas is a nearly perfect fuel. When ignited, it releases nearlythree times the energy of comparable amounts of fossil fuels and isgenerally environmentally “friendly” producing only water as aby-product of combustion. The supply of oxygen is nearly inexhaustibleas the product of the electrolysis of water through which water is splitinto hydrogen and oxygen in an atomic ratio of 2:1. However, hydrogen asa fuel has one very serious drawback: it is highly explosive and thusdangerous to store and to transport in even moderate quantities. It hasnot been reasonably practical to use hydrogen gas as a fuel, or even asa fuel additive to increase energy output of fossil fuels. Unlike mostcommon fuels, transporting an adequate quantity of hydrogen in areasonable volume would require storage under high pressure (in excessof 1,000 psi) thereby increasing risk of serious explosions. If adequatequantities could be produced on demand near or at the point ofconsumption, much of the risk would be overcome.

Much of the effort directed to the use of hydrogen as a fuel, or as afuel additive has focused on hydrogenerators (frequently referred to aselectrolyzer electrolysis devices, or electrolysis chambers. Mostrecently this emphasis is reflected in the explosive growth of researchin the general field of hydrogen fuel cell technology as it relates toboth the use of hydrogen as a fuel and to devices and systems thatsafely produce hydrogen for consumption directly or indirectly as afuel.

Numerous patents illustrate the efforts and emphasis placed on improvingthe safety of use of hydrogen by improving the safety of electrolysisdevices and systems that generate hydrogen gas. In related efforts,emphasis has also been placed on producing hydrogen at the point ofconsumption and on producing it more “on demand” to minimize the needfor storing large quantities of the explosive gas and reduce exposure torisks at all levels from production to consumer to “by-standers”.

For example, U.S. Pat. No. 5,231,954 issued to Stowe in August 1993describes a design for an electrolysis system with power to drive thesystem supplied by a vehicle electrical system. The system rapidly moveshydrogen generated in an electrolysis chamber to the fuel deliverysystem of a vehicle, thereby minimizing the storage of the hydrogen. Thesystem of the Stowe patent also includes a “pop-off” valve to ventexcessive hydrogen and reduce storage of large quantities of hydrogengas under pressure.

Deficiencies however include the absence of a means to regulate thelevel of hydrogen produced in terms of demand or even in terms ofspecific types of engines. There are also inefficiencies in hydrogen gasproduction associated with the design of electrical conductor plates inthe electrolyzer and the fact that the initiation of hydrogen gasproduction is delayed when the system is activated. Excessive heating inthe electrolyzer chamber is also a problem. The Stowe patent fails torecognize possible relevance of the electrolytic solution as it relatesto several of these deficiencies.

U.S. Pat. No. 5,733,421 issued Mar. 31, 1998 to Pettigrew, et al.overcomes several of the above cited deficiencies of the Stowe patent.Compared with the Stowe patent, the electrolysis unit of the Pettigrewpatent reduces explosion hazard by a sealed system that is protectedfrom explosions and from corrosive damage. However, the Pettigrew patentdoes not recognize the role the electrolytic solution plays in corrosionand related costs, nor apparently does the patent recognize thatuniquely designed conductor plates may benefit from a uniquelyformulated electrolytic solution.

The Stowe patent does note that a wide variety of electrolytic solutionscan be used. These include potassium hydroxide, potassium nitrate,sodium sulfate, and sulfuric acid. Without explanation, potassium issuggested as preferred; sulfuric acid yielded the greatest outputs ofhydrogen, but owing to its extreme corrosive potential is destructive tothe system. According to the disclosure of the Stowe patent only waterneed be added to the electrolyzer once the electrolysis solution(potassium hydroxide) is supplied. The Stowe patent makes no claim orrecommendation or other teaching as to superior electrolytic solutions.

U.S. Pat. No. 5,843,292 issued Dec. 1, 1998 to Spiros, describes a cellarrangement for the electrolysis of water (hydrogen production). TheSpiros patent does address complex details of anode and cathodeelectrode elements. The relevance of an electrolysis solution is “priorart” according to the Spiros patent. The Spiros patent acknowledges thatelectrolyzing water in the presence of an electrolyte is well known.Without explanation, the Spiros patent suggest potassium hydroxide andsodium hydroxide as appropriate electrolytes. The Spiros patentsummarized the process of electrolysis in its simplest terms.Electrolyzing water in the presence of NaOH or KOH to liberate hydrogeninvolves applying a DC potential difference between two or moreanode/cathode pairs and delivering the minimum energy to break the H—Obonds. Gases are produced in the stoichiometric chemical proportions of2:1/H:O. The patent '292 teaches no uniqueness to specific types ofelectrolytes.

Although the Spiros patent failed to address the possible importance ofthe nature of the electrolyte, it describes a method to selectivelyadjust the water/electrolyte pressure differential on the respectivesides of separation membranes in a hydrogen generator, thereby affectingthe release of hydrogen and oxygen. Although apparently unrecognized atthe time, this suggests far more than a simple, common role for anyelectrolyte, under at least some conditions.

There remains room in the art for improvement of the various elements ofthe emerging, complex hydrogen/oxygen generator (electrolysis) systems.Specifically, there remains room in the art for improvements informulating specific electrolytic solutions that improve the efficiencyor overall performance of any of the generally described systems as wellas for electrolytes that are more specifically formulated for certaintypes or configurations of the anode and cathode electrical elements andrelated systems.

SUMMARY OF THE INVENTION

The present invention is intended for and adapted for use in varioustypes of electrolysis systems. It has specific applications to thewelding equipment described and claimed in U.S. Pat. No. 6,689,259issued to Klein on Feb. 10, 2004, which US patent is hereby incorporatedby reference in its entirety.

A first objective of the invention is described electrolytic solutionsthat increase the efficiency of all types of electrolysis hydrogengenerating systems, including those used in welding systems, enginesystems, among others.

A further objective of the invention is to provide electrolyticsolutions that help minimize maintenance of and repairs to electrolysishydrogenerating systems and also reduce hydrogen sludge production bysuch systems.

A still further objective of the invention is to provide electrolyticsolutions adapted to hydrogen generators with conductive plates ofunique configuration or composition of conductive materials.

An additional objective of the invention is to provide electrolyticsolutions that generate higher amperage draw than generic electrolyticsolutions.

And yet another objective of the invention is to provide electrolyticsolutions that will allow the electrolysis system to operate atsubfreezing temperatures.

A still further objective of the invention is to provide electrolyticsolutions formulated from a major and a secondary set of solutes whichare dissolved in water to produce desired electrolytic solutions ofpredictable performance with specified electrolysis systems.

These and other objectives, purposes and benefits can be achieved by theherein disclosed electrolytic solutions that are stable in theelectrolysis system and the composition of which can readily be changedby altering the relative proportion of one or more solutes in either themajor or the secondary set of solutes prior to dissolving such salutesin water. These and other objectives are further satisfied byelectrolytic solutions that generate an increased amperage draw andrelated increased hydrogen gas yield compared to a standard, and furtherby desired electrolytic solutions that because of their chemicalcomposition have a freezing point below 32° F., and further by describedelectrolytic solutions that have minimum iron content and minimumcalcium salts to reduce the accumulation of hydrogen sludge and reducemaintenance of the electrolysis system. Finally, these objectives aresatisfied by desired electrolytic solutions comprised of two sets ofsolutes in which the most abundant solutes are in the major set and thelesser abundant salutes are in the minor set such that a quantity of afinal solution is made by mixing weighed amounts of each set of salutesin a quantity of water, such as two pounds of the mixed solutes in twogallons of water to yield a solution with 35% solutes, 80% of which camefrom the major set of salutes comprising predominately potassiumhydroxide and potassium carbonate and in which iron and calciumcompounds are minimized and the second set comprises a bicarbonate andsodium chloride in comparatively small amounts.

Generally, the invention is an electrolytic solution comprising:

-   -   a major solute and a minor solute combined proportionately and        dissolved in a predetermined quantity of water;    -   said major solute comprising dry pellets, flakes or combinations        thereof comprising about 83% to 87% potassium hydroxide and        about 0.4% to 0.7 of a carbonate, said major solute further        comprising minimal amounts of iron compounds and minimal amounts        of calcium; and    -   said minor solute comprising about 4.0% to 6.0% of a bicarbonate        and up to 3.0% sodium chloride,    -   wherein said solutes are combined with said predetermined        quantity of water to yield said electrolytic solution.

The dry pellets, flakes or combinations thereof comprise about 86%potassium hydroxide and about 0.6% of the carbonate. The carbonate ofthe major solute is preferably potassium carbonate. The minimal amountsof iron compounds in the major solute is preferably less than 0.005%.

The minor solute preferably comprises about 5.0% of the bicarbonate andup to 3.0% of the sodium chloride.

The electrolytic solution can be made with approximately two pounds ofcombined solutes being dissolved in approximately two gallons of waterto yield an electrolytic solution comprising approximately 28% of themajor solute and 7% of the minor solute totaling 35% total solutes.

The resultant solution is stable in reaction with an electrolysissystem, has a freezing point of at least 54° F. below the freezing pointof water, generates hydrogen gas output in an efficient manner withrespect to energy input and with respect to hydrogen output, is readilymodified in terms of the composition of its major solute to yieldsuperior performance in response to changes in the composition andconfiguration of electrical conducting elements of the electrolysissystem, and minimizes production of hydrogen sludge in the electrolysissystem and scaling of conductive and other surfaces exposed to saidelectrolytic solution.

The major solute can be modified to best adapt the solution to anelectrolytic system in which the content of nickel in conductor elementshas been altered from 14.0%.

A chemical composition of the solution can be modified by changing thecomposition of the minor solute.

These and other features, aspects and advantages of the presentinvention will become better understood with reference to the followingexamples, descriptions and appended claims.

DETAILED DESCRIPTION OF THE INVENTION

All generators depending on the electrolysis of water to produce someform of hydrogen gas use some formulation of generic electrolyticsolution. Commonly, the solute is potassium hydroxide, sodium hydroxide,or sodium bicarbonate. Little attention has been accorded the specificformulation of generic electrolytic solutions or to possiblerelationships between the formulation and unique characteristics of anelectrolysis system, particularly to the nature of the electricalconductive elements of the system with respect to efficiency of thesystem as well as to maintenance issues.

Both the system efficiency and maintenance of the electrolysis systemdescribed in U.S. Pat. No. 6,689,259 issued Feb. 10, 2004 to Klein andhereby by incorporated in its entirety by reference are affected by theformulation of the desired electrolytic solution. In one example offormulations, a described electrolytic solution comprises two sets ofsolutes and a solvent. Although “tap water” can be used, in situationsin which such water is high in dissolved salts, the use of distilled,deionized water may be appropriate.

The two sets of solutes comprise a first major set of solutes and asecond minor set of solutes. The major set provides the majority of thereactive, dry, flaked or powered (ionizing) materials. In the presentexample, the first set comprised potassium hydroxide and a carbonate,preferably potassium carbonate. The dry material preferably comprisesover 85 percent potassium hydroxide and less than 1 percent, preferablyless than 0.66 percent potassium carbonate. The remaining approximately14 percent is non-essential to the major solute and resulting solution,except iron compounds and calcium compounds are held to a minimum. Othermaterials include, but are not limited to nitrogen, phosphorous,sulfates, heavy metals, sodium, silicates, aluminum, arsenic, andmercury. The first set of solutes is commercially available as potassiumhydroxide tablets.

The second set of solutes comprises a bicarbonate, preferably potassiumbicarbonate and sodium chloride.

EXAMPLE 1

An example of an electrolysis solution in which the analysis of thefirst set of solutes are as follows: percent by weight compound limitstypical potassium hydroxide 86.00 86.30 potassium carbonate 0.60 0.50nitrogen 0.0005 0.0003 phosphorous 0.0002 0.0001 sulfates 0.0005 0.0005heavy metals (as Ag.) 0.0005 0.0005 iron (Fe) 0.0005 0.0005 sodium (Na)0.02 0.02 silicates 0.002 0.0001 aluminum 0.0001 0.0001 calcium 0.0010.0004 arsenic 0.002 0.0001 mercury 0.1 ppm 0.1 ppm identification topass (NF) conforms insoluble substances to pass (NE) passes sodium topass (NW) passes

and in which the second solute includes: a bicarbonate 5.00 sodiumchloride 2.0

Quantities of each of the solutes commonly in dry form are combined toyield the active ingredients that in the above example were 80 percentof the first solute and 20 percent of the second. Two pounds of theactive ingredients are added to approximately two gallons of water toproduce an electrolytic solution that is 28 percent of the major soluteand 7 percent of the minor solute, and a total of 35 percent of thesolutes, total. One skilled in the art recognizes that this finalcomposition can be reached by mixing other combinations of basicingredients.

The freezing point of the above-described electrolytic solution wasapproximately −22° F., substantially lower than the freezing point ofwater, that is, at least 54° F. below the freezing point of water, andat least comparable to the freezing point of generic electrolyticsolutions, such as a 20% percent solution of potassium hydroxide with afreezing point of +25° F.

The described electrolytic solution was used in an electrolysis systemreferenced in U.S. Pat. No. 6,689,259 that generates a combustible gasfrom water for a welder. In that specific electrolysis system, theelectrolyzer produced an amperage draw of 20 amps compared with a drawof 18 amps using a generic electrolytic solution. Amperage draw(electrical power) production is highly, positively correlated with thelevel of gas (fuel) generation; thus the described electrolytic solutioncaused the generation of more gas (fuel) than the same electrolysissystem produced with a generic electrolytic solution. In this system,the conductive elements (plates) of the electrolyzer were ferrous with14% nickel. Changing, increasing the percent nickel to about 20% andusing the a generic electrolytic solution, resulted in a reduced gasyield; however when the generic electrolytic solution was modified tohave 85% of the major solute, or a total of 35% solutes, resultant gasproduction equaled or exceeded that of the initial system using theinitially described conductive elements (plates). The combustible gas isstable with respect to a given electrolysis system but the use ofdescribed electrolytic solutions increases electrical efficiencies,therefore increasing combustible gas production.

The system in which the described electrolytic solution was used alsooperated more efficiently with respect to maintenance wear, and generalupkeep. Compared with generic electrolytic solutions, less calciuminduced scaling was detected in the electrolyzer and the production ofhydrogen sludge was substantially reduced.

The reduced scaling and substantial reduction of hydrogen sludgeproduction is a direct reflection of the effective elimination of ironand calcium compounds in the described electrolytic solutions. Thereduced freezing point is a desired function of the level and types ofsolutes in the described electrolytic solutions. The increased poweroutput and resultant increase in combustible gas production resultedfrom the stability of the described electrolytic solutions in thesystems, the dissociation of the salts in specific proportions and aninteraction between the formulation of the described electrolyticsolutions and the composition and configuration of electrical conductorelements (plates) in the electrolysis system, specifically reflected inthe reaction to moderate changes in the proportion of nickel in theconductor elements (plates).

EXAMPLE 2

The above-described electrolytic solution was modified by altering therelative proportion of potassium hydroxide and potassium carbonate inthe major solute as shown in the table below. The table shows ranges ofthe resultant increase of amperage draw across 14% nickel (6″×6″)plates. Amperage draw increase ranged from 140 amps to 165 amp. Moreamperage draw produces more gas volume. Voltage remained constant at 12volts DC. Amperage Draw Electrolyte Solution: 140 amps 152 amps 158 amps165 amps Potassium Hydroxide 28%  28%  28%  28%  Bicarb 0% 2% 3% 5%Sodium Chloride 0% 1% 2% 3%

In addition, the proportion of nickel in the conductive elements(plates) in the electrolysis system ranges from 14% to 99.99% percent.General performance decreased for the generic electrolytic solutions,but still was effective. However the new electrolytic solutions producedsuperior results. Amperage draw increased with parallel increases incombustible gas output, increased efficiency of the inputted electricalenergy, and reduced maintenance continued.

The preceding descriptions and examples are for illustrative purposes,not limitations on the scope or intent of the invention. It isanticipated that various elements of the several examples may becombined to yield still more valuable, alternative electrolyticsolutions all of which are anticipated by the invention. Thus is anyinterpretation of the examples results, formulations, and compositionsof equipment are to be accorded their widest possible meaning and not beinterpreted as limitations on the scope or intent of the invention.

1. An electrolytic solution comprising: a major solute and a minor solute combined proportionately and dissolved in a predetermined quantity of water; said major solute comprising dry pellets, flakes or combinations thereof comprising about 83% to 87% potassium hydroxide and about 0.4% to 0.7 of a carbonate, said major solute further comprising minimal amounts of iron compounds and minimal amounts of calcium; and said minor solute comprising about 4.0% to 6.0% of a bicarbonate and up to 3.0% sodium chloride, wherein said solutes are combined with said predetermined quantity of water to yield said electrolytic solution.
 2. The electrolytic solution according to claim 1, wherein the dry pellets, flakes or combinations thereof comprise about 86% potassium hydroxide and about 0.6% of the carbonate.
 3. The electrolytic solution according to claim 1, wherein the carbonate of the major solute is potassium carbonate.
 4. The electrolytic solution according to claim 1, wherein the minimal amounts of iron compounds in the major solute is less than 0.005%.
 5. The electrolytic solution according to claim 1, wherein the minor solute comprises about 5.0% of the bicarbonate and up to 3.0% of the sodium chloride.
 6. The electrolytic solution according to claim 1, wherein approximately two pounds of combined solutes are dissolved in approximately two gallons of water to yield an electrolytic solution comprising approximately 28% of said major solute and 7% of said minor solute totaling 35% total solutes.
 7. The electrolytic solution according to claim 1, wherein said electrolytic solution is stable in reaction with an electrolysis system, has a freezing point of at least 54° F. below the freezing point of water, generates hydrogen gas output in an efficient manner with respect to energy input and with respect to hydrogen output, and minimizes production of hydrogen sludge in the electrolysis system and scaling of conductive and other surfaces exposed to said electrolytic solution. 